The above output shows that there are two hard disks (hda and hdc). Partitions are visible on hda however hdc does not contain a valid partition table. In fact this is the replacement for the faulty disk.

Note that [2/1] shows that there are 2 disks in the array however only 1 is active. The symbols [_U] mean that one of the two disks is missing from the array and must be reconfigured.

Since the new disk is /dev/hdc we need create the partitions required for the RAID. Use fdisk to create the boot partition on the new disk.

[root@mail ~]# fdisk /dev/hdc
Device contains neither a valid DOS partition table, nor Sun, SGI or OSF disklabel
Building a new DOS disklabel. Changes will remain in memory only,
until you decide to write them. After that, of course, the previous
content won't be recoverable.

The number of cylinders for this disk is set to 60801.
There is nothing wrong with that, but this is larger than 1024,
and could in certain setups cause problems with:
1) software that runs at boot time (e.g., old versions of LILO)
2) booting and partitioning software from other OSs
(e.g., DOS FDISK, OS/2 FDISK)
Warning: invalid flag 0×0000 of partition table 4 will be corrected by w(rite)

Software RAID requires disks in the array to be partitioned identically. You can try to do this manually calculating the exact number of cylinders required for each partition to match their counterparts on the other disk. This is highly discouraged. Instead we use the sfdisk command.